System and method for remotely managing the flow of water through a rotating control device

ABSTRACT

An actuation system for a drill rig, the drill rig having a rig floor, a rotating control device positioned below the rig floor, and a water line in fluid communication with the rotating control device, is provided for management of the flow of water from the water line to the rotating control device from above the rig floor. The actuation system includes a controller positioned above the rig floor, a control valve, and a communication line. The control valve is positioned between the water line and the rotating control device. The control valve is moveable between an open and a closed position. The communication line provides communication between the controller and the control valve so that the control valve manages the flow of water from the water line to the rotating control device.

TECHNICAL FIELD

The present disclosure relates generally to an actuation system, and, more particularly, to an actuation system and method for remotely managing the flow of water through a rotating control device into the wellbore from above the rig floor.

BACKGROUND

Rotating control devices provide a protective seal about a drill string during drilling operations. When engaged with the drill string, the rotating control device precludes release of wellbore fluids, such as drilling mud, to the atmosphere. Drilling mud carries rock cuttings to the surface and lubricates and cools the drill bit during drilling operations. To provide more efficient drilling operations, it may be desirous to reduce the weight of the drilling mud. The weight of drilling mud is reduced through the introduction of a fluid such as water into the drilling mud. Water is flowed into the drilling mud through the annulus between the casing wall and the drill string.

Rotating control devices provide fluid communication between fresh water and the annulus between the casing wall and the drill string. The flow of water is controlled through the manipulation of a valve. Manipulation of the valve requires rig personnel to go below the rig floor to access the valve. Such activity during drilling operations creates additional risk for the rig personnel and causes unnecessary downtime for the well drilling site. These deficiencies in current rotating control devices prompt the need for a water fill system that can be operated remotely from above the rig floor.

SUMMARY

The present invention provides a system and method for managing the flow of water through a rotating control device which overcomes the deficiencies described above, and has other advantages.

In one embodiment, an actuation system for a drill rig, the drill rig having a rig floor, a rotating control device positioned below the rig floor, and a water line in fluid communication with the rotating control device is provided. The actuation system comprises a controller positioned above the rig floor, a control valve, and a communication line. The control valve is positioned between the water line and the rotating control device to manage the flow of water from the water line to the rotating control device. The control valve has an open and a closed position. The communication line provides communication between the controller and the control valve.

In another embodiment, an actuation system for a drill rig, the drill rig having a rig floor, a rotating control device positioned below the rig floor, and a water line in fluid communication with the rotating control device is provided. The actuation system comprises a controller positioned above the rig floor, a pneumatic valve, and an air line. The pneumatic valve is positioned between the water line and the rotating control device to manage the flow of water from the water line to the rotating control device. The pneumatic valve has an open and a closed position. The air line provides sufficient fluid communication between the controller and the pneumatic valve to actuate the pneumatic valve between the open and closed positions.

In another embodiment, the control valve is an electrical solenoid valve. The communication line provides sufficient electrical communication between the controller and the electrical solenoid valve to actuate the electrical solenoid valve between the open and closed positions.

In another embodiment, there is provided a method for remotely managing the flow of water from a water line to the rotating control device comprising the steps of: positioning a rotating control device below a rig floor of a drill rig, the rotating control device in fluid communication with a water line; positioning a controller above the rig floor; positioning a control valve between the water line and the rotating control device; providing communication between the controller and the control valve with a communication line; and communicating from the controller to the control valve to actuate the control valve between an open and a closed position so that the control valve manages the flow of water from the water line to the rotating control device.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included with this application illustrate certain aspects of the embodiments described herein. However, the drawings should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, as will occur to those skilled in the art with the benefit of this disclosure.

FIG. 1 is a generalization of a drill rig in accordance with one embodiment of the present disclosure.

FIG. 2 is a perspective side view of a portion of the actuation system for controlling the water line in accordance with one embodiment of the present disclosure.

FIG. 3 is a perspective side view of a portion of the actuation system for controlling the water line in accordance with one embodiment of the present disclosure.

FIG. 4 is a perspective front side view of a pneumatic valve in accordance with one embodiment of the present disclosure.

FIG. 5 is a perspective front side view of an air control valve in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure may be understood more readily by reference to these detailed descriptions. For simplicity and clarity of illustration, where appropriate, reference numerals may be repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate details and features of the present disclosure.

Referring now to FIGS. 1-5 generally, a drill rig in accordance with the present disclosure is illustrated and generally designated by the numeral 10. As shown by FIG. 1, the general form of drill rig 10 includes a rig floor 20, a rotating control device 30, a water line 40, and an actuation system 50 for controlling water line 40. The structure and use of rotating control device 30 are well known and will not be discussed in detail. As depicted in FIG. 1, rotating control device 30 will be located below rig floor 20 with a drill string 12 passing through rotating control device 30. Rotating control device 30 is in fluid communication with an annulus 16 created between drill string 12 and a casing wall 14 which lines the walls of the wellbore. During drilling operations, rotating control device 30 creates a seal between rotating control device 30 and drill string 12 to prevent and preclude loss of wellbore fluids, such as drilling mud, to the environment.

To increase the efficiency of drilling operations, the weight of the drilling mud may be reduced through dilution. A common dilution fluid is water. Water line 40 provides fluid communication between a fresh water source and rotating control device 30 for dilution of the drilling mud. Water is flowed through water line 40 into rotating control device 30 which provides fluid communication between water line 40 and annulus 16. Thus, water is flowed through water line 40 into rotating control device 30 and into annulus 16 where the water mixes with and dilutes the drilling mud as it flows up through the annulus 16.

Actuation system 50 operates to manage the dilution of the drilling mud by controlling the flow of water from water line 40 through rotating control device 30 and into annulus 16. The general form of actuation system 50 comprises a controller 60, a control valve 70, and a communication line 80. Controller 60 is located above rig floor 20 and provides the rig operator with operational control of actuation system 50. Operation of controller 60 will remotely actuate control valve 70 into and out of its open and closed positions. In an open position, control valve 70 allows fresh water to pass through water line 40 to rotating control device 30 and into annulus 16. In a closed position, control valve 70 restricts the flow of fresh water through water line 40 to rotating control device 30 and into annulus 16.

Controller 60 is selected for its ability to manage the operation of control valve 70. Those skilled in the art will be familiar with controllers suitable for managing the operation of control valve 70 as many such controllers are commercially available. The primary requirement being that controller 60 has the ability to actuate control valve 70 between open and closed positions. As discussed below, control valve 70 may be actuated hydraulically, pneumatically, or electrically between open and closed positions. As such any of the commercially available controllers suitable for such operations will be appropriate.

Control valve 70 provides fluid communication between water line 40 and rotating control device 30. In most instances, control valve 70 will be carried by rotating control device 30; however, control valve 70 may be positioned anywhere along water line 40 with a second water line (not shown) providing fluid communication between control valve 70 and rotating control device 30. Thus, control valve 70 controls the flow of water from water line 40 into rotating control device 30. For example, control valve 70 has an open position and a closed position. In the open position, control valve 70 allows water to pass from any convenient water source through water line 40 to rotating control device 30 at a flow rate and pressure, suitable for blending with the drilling mud. In the closed position, control valve 70 precludes the flow of water into rotating control device 30. In some embodiments, control valve 70 provides the ability to vary the flow of water through water line 40 into rotating control device 30 between full open and full closed positions. Thus, during mud drilling operations, control valve 70 provides the ability to continuously adjust the drilling mud weight flowing through the wellbore by managing the volume of water entering annulus 16.

Communication line 80 provides communication between controller 60 and control valve 70. Controller 60 directs control valve 70 to actuate between open and closed positions through or over communication line 80. Depending on the type of control valve 70, controller 60 directs communication line 80 to direct sufficient fluid pressure, gas pressure, gas flow or electric current to control valve 70. Changes in fluid pressure, air pressure or electrical current will determine the open, closed or partially open positions of control valve 70.

In some embodiments, control valve 70 may be a pneumatic valve as shown in FIG. 4 and designated by numeral 72. Pneumatic valve 72 is actuated by the transmission of air from communication line 80 through one or more air ports. Pneumatic valve 72 may be a single component with control valve 70 and the pneumatic action component provided in a single integrated component or a pneumatic component (not shown) positioned to engage control valve 70. In such embodiments, communication line 80 is one or more air lines 84 as depicted in FIGS. 1-5. As depicted, pneumatic valve 72 includes air ports 73A and 73B. The transmission of air from air lines 84 is controlled to either air port 73A or air port 73B to actuate pneumatic valve 72 between the open and closed positions. Any number of air actuated valves can be used for control valve 70. For example, in some embodiments, control valve 70 may be a single air port valve or double air port valve. In other embodiments, control valve 70 includes a flap within control valve 70. The transmission of air to control valve 70 actuates the flap to a closed position. Restricting the transmission of air to control valve 70 releases the flap to an opened position. Thus, water flows from water line 40 into rotating control device 30 and into annulus 16 when control valve 70 is in an opened position.

In some embodiments, when control valve 70 is a pneumatic valve, controller 60 may be an air control valve, such as depicted in FIG. 5. As shown in FIG. 5, controller 60 is a multi port air control valve and generally designated by the numeral 62. Air control valve 62 includes an air intake port 63A, an air exhaust port 63B, two air output ports 63C and 63D, and a handle 64. Air intake port 63A is fluidly connected to an air supply line 82. Air lines 84 provide fluid communication between air control valve 62 and control valve 70 through connection to air output ports 63C and 63D. Air exhaust port 63B is fluidly connected to air exhaust line 86 and provides the release of pressure from air lines 84.

Handle 64 has one or more positions. A center position of handle 64 exhausts air through air exhaust port 63B. An up position of handle 64 directs air to air output port 63C to actuate control valve 70 into a first position. A down position of handle 64 directs air to air output port 63D to actuate control valve 70 into a second position. The first and second positions of control valve 70 allow or restrict water to pass from water line 40 to rotating control device 30. When handle 64 is in the up position or the down position, air exhaust port 63B simultaneously releases air through air exhaust line 86 from whichever of air output port 63C or air output port 63D is not having air directed to it for actuating control valve 70.

In other embodiments, control valve 70 actuates through the transmission of an electric current. For example, control valve 70 may be an electrical solenoid valve. As with the pneumatic arrangement, the electrical solenoid valve may be integrated with control valve 70 or a separate component positioned to engage and actuate control valve 70. Controller 60 provides a suitable electric current over communication line 80 to actuate the electrical solenoid valve between open and closed positions. The transmission of an electrical current engages and restricts movement of the solenoid within the electrical solenoid valve in a closed position or disengages and releases the solenoid within the electrical solenoid valve to allow free movement when in an opened position.

Although the disclosed invention has been shown and described in detail with respect to a preferred embodiment, it will be understood by those skilled in the art that various changes in the form and detailed area may be made without departing from the spirit and scope of this invention as claimed. Thus, the present invention is well adapted to carry out the object and advantages mentioned as well as those which are inherent therein. While numerous changes may be made by those skilled in the art, such changes are encompassed within the spirit of this invention as defined by the appended claims. 

1. An actuation system for a drill rig, the drill rig having a rig floor, a rotating control device positioned below the rig floor and in fluid communication with an annulus, and a water line in fluid communication with the rotating control device, the actuation system comprising: a control valve positioned between the water line and the rotating control device, wherein the control valve manages the flow of water from the water line into the rotating control device by moving between an open position and a closed position; and a controller positioned above the rig floor in communication with the control valve such that the controller actuates the control valve between the open position and the closed position, wherein the actuation system is configured such that, when the control valve is in the open position, water flows into the rotating control device and into the annulus to mix with a drilling mud such that the weight of the drilling mud is reduced.
 2. The actuation system of claim 1, wherein the control valve is a pneumatic valve.
 3. The actuation system of claim 2, wherein the controller is in communication with the control valve with an air line, the air line providing sufficient fluid communication between the controller and the pneumatic valve to actuate the pneumatic valve between the open position and the closed position.
 4. The actuation system of claim 3, wherein the controller is an air control valve.
 5. The actuation system of claim 1, wherein the control valve is an electrical solenoid valve in electrical communication with the controller.
 6. An actuation system for a drill rig, the drill rig having a rig floor, a rotating control device positioned below the rig floor and in fluid communication with an annulus, and a water line in fluid communication with the rotating control device, the actuation system comprising: a pneumatic valve positioned between the water line and the rotating control device, wherein the pneumatic valve manages the flow of water from the water line into the rotating control device by moving between an open position and a closed position; and a controller positioned above the rig floor in communication with the pneumatic valve with an air line such that the controller actuates the pneumatic valve between the open position and the closed position with air, wherein the actuation system is configured such that, when the pneumatic valve is in the open position, water flows into the rotating control device and into the annulus to mix with a drilling mud such that the weight of the drilling mud is reduced.
 7. The actuation system of claim 6, wherein the controller is an air control valve.
 8. A method comprising: positioning a rotating control device below a rig floor of a drill rig, the rotating control device in fluid communication with an annulus and a water line; managing the flow of water from the water line into the rotating control device by moving a control valve positioned between the water line and the rotating control device between an open position and a closed position; positioning a controller in communication with the control valve above the rig floor such that the controller actuates the control valve between the open position and the closed position; flowing a drilling mud up through the annulus and into the rotating control device; and reducing the weight of the drilling mud by communicating from the controller to the control valve to actuate the control valve from the closed position to the open position such that water flows into the rotating control device and the annulus to mix with the drilling mud.
 9. The method of claim 8, wherein the control valve is a pneumatic valve.
 10. The method of claim 9, wherein the controller is in communication with the pneumatic valve with an air line such that the controller actuates the pneumatic valve between the open position and the closed position with air.
 11. The method of claim 10, wherein the controller is an air control valve.
 12. The method of claim 8, wherein the control valve is an electrical solenoid valve in electrical communication with the controller. 